Viessmann VITOCAL 242-G Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitocal 242-G/222-G
Type CHE
Compact Energy Tower for low energy houses
For applicability, see the last page
VITOCAL 242-G/222-G
5592 969 GB 9/2007 Please keep safe.

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&the Code of Practice of relevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5592 969 GB

Working on the system
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5592 969 GB

Installation instructions
Preparing for installation
Transport.................................................................................................... 9
Positioning ................................................................................................. 9
Overview of available system versions ........................................................ 13
Function description of systems .................................................................. 14
System version on the primary side............................................................. 18
System version 1 ........................................................................................ 19
System version 2 ........................................................................................ 27
System version 3 ........................................................................................ 36
System version 4 ........................................................................................ 45
Installation sequence
Summary of electrical connections.............................................................. 55
Preparing the installation ............................................................................ 56
Fitting the water drain (Vitocal 242) ............................................................. 57
Fitting the water drain (Vitocal 222) ............................................................. 59
Heat pump preparation ............................................................................... 59
Installing the control module ....................................................................... 61
Inserting the heat pump .............................................................................. 62
Inserting the cables .................................................................................... 64
Connecting the external electrical components ........................................... 66
Power supply.............................................................................................. 74
Checking the rotating field of the power supply............................................ 87
Installing a 400 V full wave soft starter (as of BWT 108) ............................... 87
Installing a 230 V full wave soft starter (all models)...................................... 89
Making the electrical heat pump connections .............................................. 91
Connecting the brine pressure switch or a jumper........................................ 92
Connecting the secondary circuit ................................................................ 93
Connection panel........................................................................................ 94
Connecting the DHW .................................................................................. 94
Connecting the heating circuit..................................................................... 96
Connecting the solar circuit (option, only for the Vitocal 242) ....................... 97
Connecting the brine side ........................................................................... 98
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 99
Further details regarding the individual steps .............................................. 101
Troubleshooting
Control unit diagnostics .............................................................................. 123
Diagnosis ................................................................................................... 130
Index
4
Index
5592 969 GB

Control settings
Menu structure overview –Main menu ........................................................ 133
Menu structure overview –information ........................................................ 134
Menu structure overview –Programming..................................................... 135
Menu structure overview –Contractor level ................................................. 138
Control settings by contractors.................................................................... 142
Activating the technical service level ........................................................... 142
Adjusting sensor temperatures.................................................................... 143
Checking signal inputs................................................................................ 144
Manual control of relays and mixers ............................................................ 144
Control unit settings –system definition
System design............................................................................................ 147
Power-OFF contact: 1S............................................................................... 147
Average time; outside temperature.............................................................. 147
Heating limit < T room (heating limit temperature)........................................ 148
Temperature limit for reduced temperature mode......................................... 148
Frost protection temperature....................................................................... 149
Heat pump control settings
Power-OFF compressor.............................................................................. 150
Maximum flow temperature ......................................................................... 150
Minimum return temperature ....................................................................... 150
Hysteresis T primary/min. T primary in ........................................................ 151
Minimum runtime ........................................................................................ 152
Min. compressor off .................................................................................... 152
Flow; primary/secondary pump ................................................................... 152
Optimum runtime ........................................................................................ 153
Electric heater control settings
E heating .................................................................................................... 155
Power-OFF; instantaneous heating water heater......................................... 155
Electric heating........................................................................................... 155
DHW with electric power ............................................................................. 156
Maximum flow temperature ......................................................................... 156
Heater rod delay ......................................................................................... 157
Electric heating threshold ........................................................................... 157
Maximum stage; electric heater................................................................... 158
Internal hydraulics control settings
Heat pump for drying buildings.................................................................... 159
Time for drying buildings ............................................................................. 159
Flow hysteresis........................................................................................... 160
Index (cont.)
5
Index
5592 969 GB

Internal pump run-on................................................................................... 160
Max. steps; three-way valve........................................................................ 160
Solar collector control settings (only for the Vitocal 242)
Solar collector ............................................................................................ 162
Maximum temperature ................................................................................ 162
Solar pump hysteresis ON/solar pump hysteresis OFF ................................ 162
Pump kick hysteresis .................................................................................. 163
Pump kick runtime ...................................................................................... 164
Pump kick dead time................................................................................... 165
Flow rate .................................................................................................... 165
DHW control settings
DHW cylinder temperature .......................................................................... 166
DHW program temperature ......................................................................... 166
DHW circulation pump program................................................................... 166
Operating mode.......................................................................................... 166
DHW cylinder maximum.............................................................................. 167
Hysteresis; DHW instantaneous heating water heater/hysteresis................. 167
Start optimisation........................................................................................ 169
Stop optimisation........................................................................................ 169
DHW auxiliary function................................................................................ 169
Set DHW temperature 2 .............................................................................. 169
Heat pump cylinder volume......................................................................... 169
Excess reaction .......................................................................................... 170
Maximum DHW runtime .............................................................................. 170
Maximum DHW interruption ........................................................................ 170
Heating circuit control settings
Standard temperature................................................................................. 172
Reduced temperature ................................................................................. 172
Temperature program, heating circuit .......................................................... 172
Remote control ........................................................................................... 172
Operating mode.......................................................................................... 172
Maximum flow temperature ......................................................................... 173
Minimum flow temperature .......................................................................... 173
DHW during party mode.............................................................................. 174
Excess reaction .......................................................................................... 174
Room temperature sensor........................................................................... 175
Slope; room temperature hook-up ............................................................... 175
Room temperature hook-up ........................................................................ 176
Start optimisation........................................................................................ 176
Maximum flow temperature correction......................................................... 176
Index (cont.)
6
Index
5592 969 GB

Room temperature control .......................................................................... 177
Adjusting the heating curve level and slope ................................................. 178
Integral room temperature controller ........................................................... 178
Flow T excess ............................................................................................. 178
Mixer runtime.............................................................................................. 179
Mixer parameters........................................................................................ 179
Screed function .......................................................................................... 180
Mixer active zone/dead zone....................................................................... 181
Natural cooling ........................................................................................... 182
Cooling limit > T room (cooling limit temperature) ........................................ 183
Cooling curve level/slope............................................................................ 183
Natural cooling with mixer ........................................................................... 184
Active zone/dead zone natural cooling mixer............................................... 185
Cooling mixer runtime ................................................................................. 185
Cooling mixer parameters ........................................................................... 186
Buffer cylinder control settings
Buffer cylinder ............................................................................................ 187
Buffer cylinder program............................................................................... 187
Fixed temperature ...................................................................................... 187
Hysteresis temperature............................................................................... 188
Maximum temperature ................................................................................ 188
Stop optimisation........................................................................................ 189
Excess reaction .......................................................................................... 189
Components
Sensor resistance curves............................................................................ 191
Fuse........................................................................................................... 192
Connection and wiring diagrams
Overview of the PCBs and connection options............................................. 193
Main connection area.................................................................................. 194
Safety chain, 400 V units............................................................................. 196
Safety chain, 230 V units............................................................................. 197
Left part of the main PCB ............................................................................ 198
Upper and lower part of the main PCB......................................................... 200
R.h. part of the main PCB............................................................................ 202
Parts lists
Parts list Vitocal 242-G ............................................................................... 204
Parts list Vitocal 222-G ............................................................................... 210
Index (cont.)
7
Index
5592 969 GB

Commissioning/service reports
Hydraulic parameter report ......................................................................... 216
Control parameter report............................................................................. 217
Specification for 400 V devices ................................................................ 222
Specification for 230 V devices ................................................................ 226
Appendix
Order to commission the Vitocal 242/222 .................................................... 229
Certificates
Declaration of conformity ............................................................................ 230
Declaration of conformity ............................................................................ 231
Keyword index .......................................................................................... 232
Index (cont.)
8
Index
5592 969 GB

Please transport the unit in the crate
to protect it from damage. The crate
can be dismantled if the amount of
available space is limited.
Leave the pallet beneath the unit for
transportation.
We recommend you transport the
equipment on a Viessmann trolley.
Secure the unit with tension straps.
The max. permitted tilting angle for
the compressor during transportation
and installation is 30°.
!Please note
To avoid damage during trans-
portation without the pallet,
never put weight onto the top,
front or side walls of the unit.
Never support the equipment
on its front or side panels.
Standard dimensions when tilted
Equipment on pal-
let
2 395 mm
Equipment alone 2 085 mm
Positioning
Installation room requirements
Required room height when utilising
the connection panel: 2400 mm (min).
Note
To prevent damage to the building
structure, please pay attention to the
permissible load-bearing capacity of
the floor.
Type Total weight incl. DHW
kg
BWT 106 520
BWT 108 530
BWT 110 535
The installation room must be dry and
safe from the risk of frost.
To prevent corrosion damage, provide
the brine-side heat pump installation
with thermal insulation in accordance
with current rules as vapour diffusion
proof installation.
To prevent structure-borne noise,
never set up the unit on wooden ceil-
ings in the attic.
Transport
9
Preparing for installation
5592 969 GB
Installation

Top panel dimensions (plan view)
ACable entry (length of cables in
unit approx. 1300 mm)
BPrimary outlet
CPrimary inlet
DHydraulic connection array
Positioning (cont.)
10
Preparing for installation
5592 969 GB

Clearance dimensions (plan view)
Amin. 1000 mm
BVitocal 242:
The required clearance for the
removal of the front panels is
20 mm. Also maintain this dimen-
sion when using decorative
frames.
Vitocal 222:
Maintain a clearance of 140 mm to
the left or right for the blow-off line
of the heating circuit safety valve.
COptionally on the l.h. or r.h. side
DVitocal 242: min. 15 mm (see
also page 57)
Vitocal 222: min. 45 mm (see
also page 59)
Maximum distance:
For distances > 80 mm fit the
power cables on site with strain
relief fittings.
Positioning (cont.)
11
Preparing for installation
5592 969 GB
Installation

On-site connection requirements
AAppliance dimensions
BRecommended outlet area of on-
site hydraulic connections (com-
pulsory when installing with a con-
nection panel)
COnly Vitocal 242:
Possible position (pipe centre) of
the on-site drain connection
DN 32 for condensate with a wall
clearance of > 45 mm
Positioning (cont.)
12
Preparing for installation
5592 969 GB

DOnly Vitocal 242:
Position (centre pipe) of the on-
site drain connection DN 32 for
condensate with a wall clearance
from 15 to 45 mm
EPossible exit area of brine-side
connections and/or on-site
cables.
FTop edge –finished floor
GOnly Vitocal 222:
Possible position (pipe centre) of
the on-site drain connection
DN 40 for the blow-off line of the
heating circuit safety valve.
Install a siphon on site
Overview of available system versions
The following table provides an overview of all possible system versions.
The designs on the following pages are representative for four typical heat
pump systems.
System
layout in-
side the
control
unit
Standard equipment Additional equip-
ment
"Natural
cooling"
(only one option
per system design)
Direct
heating
circuit
Heating
circuit
with
mixer
DHW cy-
linder
Buffer
cylinder
Low loss
header
2 X X X X
X
4 X X X X
6 X X X X X
X
Positioning (cont.)
13
Preparing for installation
5592 969 GB
Installation

Note
Never operate 230 V units in d.
A pre-requisite for operating 230 V units in some countries is that starting cur-
rents of up to 45 A are permissible in the power grid of the country concerned
(observe other country-specific regulations, if necessary).
The sample applications are recommendations and must be checked for com-
pleteness and functionality on site. Please observe the applicable regulations
and directives for design, installation and operation.
Heating circuit
Heat pumps require a minimum heat-
ing water throughput. Ensure that the
values specified in the relevant data-
sheet are maintained.
Accurately calculated radiator heating
systems generally have a small sys-
tem water content. With systems like
these, use a heating water buffer
cylinder with an appropriate capacity
to prevent the heat pump from being
switched on and off at frequent inter-
vals.
Heat pumps can be shut off by the
power supply utility at peak load peri-
ods depending on the power tariff. For
this reason a heating water buffer
cylinder should be installed for rapidly
cooling heating systems (radiators).
The volume of the heating water buf-
fer cylinder should be sufficient to pre-
vent the stored heat from allowing the
building to cool down during power-
OFF periods.
System versions 2 to 4 do not use a
secondary pump but a separate circu-
lation pump as heating circuit pump.
We recommend the use of a heating
circuit pump with a slower flow rate
than the secondary pump. Install a
heating water buffer cylinder in paral-
lel to the heating circuit to compen-
sate for the difference between these
water volumes.
Systems with large volumes, e.g.
underfloor heating systems, will not
necessarily require a heating water
buffer cylinder. In these heating sys-
tems install an overflow valve at the
underfloor heating system heating cir-
cuit distributor that is furthest away
from the heat pump. This ensures that
the minimum water circulation volume
is provided, even in closed heating
circuits.
If an instantaneous heating water
heater is installed, a temperature lim-
iter (accessory, order no. 7151 728 or
7151 729) must be installed in con-
junction with an underfloor heating cir-
cuit. Install the temperature limiter, for
example, on the underfloor heating
circuit pump.
Function description of systems
14
Preparing for installation
5592 969 GB

Heating water buffer cylinder operated in parallel
Heating water buffer cylinders provide
a hydraulic separation of the flow in
the heat pump and heating circuits.
For example, the flow rate in the heat
pump circuit remains constant, even if
the heating circuit flow rate is reduced
by thermostatic valves.
The use of a heating water buffer
cylinder offers the following advan-
tages:
&Bridging power-OFF periods
&Constant flow rate through the heat
pump
&Longer heat pump operating times
Because of the increased water
volume of the heat source and the fact
that it may have a separate shut-off
facility, an additional (or larger)
expansion vessel should be provided.
Protect the heat pump with a fuse in
accordance with DIN 4751 [or local
regulations].
Systems without heating water buffer cylinder
Never install a mixer to safeguard the
minimum heating water circulation
volume.
Natural cooling function
During the summer months the tem-
perature level of the primary circuit
can be used to cool the building.
The natural cooling function is a
method of cooling buildings that
saves a considerable amount of
energy. All that is needed is a small
amount of electricity for the circulation
pumps to access the "cooling source"
in the ground.
During the cooling operation, the heat
pump will only be started to provide
DHW. The heat pump control system
actuates the circulation pumps, diver-
ter valves and mixers and records the
temperature via the natural cooling
extension kit. Alternatively, this func-
tion can also be covered by on-site
components (for an on-site wiring
suggestion, see the Vitocal 200/222/
242 technical guide).
A contact humidistat monitors the dew
point.
The capability of the natural cooling
function cannot generally be com-
pared with that of air-conditioning
equipment or water chillers. Natural
cooling provides no dehumidification.
Function description of systems (cont.)
15
Preparing for installation
5592 969 GB
Installation

The cooling capacity depends on the
heat source temperature, which itself
is subject to seasonal fluctuations.
Experience has shown that the cool-
ing capacity is higher at the beginning
of summer than at the end.
In addition, the water source tempera-
ture curve is subject to the cooling
demand of the building. Because of
large window areas or internal
sources (lighting, electrical equip-
ment), the heat source temperature
increases more rapidly during the
course of a year than it does if less
cooling is required.
Underfloor heating systems and con-
crete core tempering are available for
cooling the building; radiator heating
systems are unsuitable for this pur-
pose. Ensure that any installed room
thermostats are able to be opened
manually or by servomotors when
using the cooling function.
DHW heating with the heat pump
In the delivered condition, domestic
hot water heating by the heat pump is
given priority in the heating circuit and
should preferably take place over-
night.
During cylinder heating, the control
unit switches the circulation pump
OFF to prevent the cylinder heating
from being impaired.
DHW heating with solar boost (only Vitocal 242)
If sufficient solar radiation is avail-
able, the DHW can be heated exclu-
sively by the solar heating system.
To optimise the solar cover, heating
the DHW cylinder by heat pump
should be limited to the upper cylinder
volume. This is achieved via an inte-
gral, manually activated three-way
diverter valve.
During cylinder heating, the control
unit switches the circulation pump
OFF to prevent the cylinder heating
from being impaired.
Function description of systems (cont.)
16
Preparing for installation
5592 969 GB

Overview of the internal components
HR Heating return
HV Heating flow
KW Cold water (connections, see
from page 94)
RL Solar return (only Vitocal 242)
VL Solar flow (only Vitocal 242)
WW DHW
Z DHW circulation
APrimary return (primary outlet)
BPrimary flow (primary inlet)
CFlow temperature sensor; sec-
ondary circuit
DInstantaneous heating water
heater
ESecondary pump
FThree-way diverter valve "Cen-
tral heating/DHW"
GPlate-type heat exchanger for
cylinder heating
HUpper cylinder temperature sen-
sor
KReturn temperature sensor of
the solar circuit (only
Vitocal 242)
LSolar circuit pump (only
Vitocal 242)
MLower cylinder temperature sen-
sor
NDHW cylinder
OSolar heat exchanger (only
Vitocal 242)
PThree-way diverter valve
(manual) (only Vitocal 242)
RCylinder primary pump
SReturn temperature sensor; sec-
ondary circuit
THeat pump module
UPrimary pump
Function description of systems (cont.)
17
Preparing for installation
5592 969 GB
Installation

Hydraulic diagram
AHeat pump interface (see from
page 19)
2Brine accessory pack
3Brine distributor for geothermal
probes/collectors
4Geothermal probes/geothermal
collectors
qQ Brine circuit pressure switch
Electrical connection
Pressure switch connection for brine circuit, qQ see page 21.
Equipment required
Pos. Description Number
2Brine accessory pack 1
3Brine distributor for geothermal probes/collectors as required
4Geothermal probes/geothermal collectors as required
qQ Brine circuit pressure switch 1
System version on the primary side
18
Preparing for installation
5592 969 GB

One directly connected heating circuit, DHW heating with solar boost
(option) and natural cooling function (option)
Note
Solar boosted DHW heating is only possible with the Vitocal 242.
To achieve this system version, select system design 2 at the control unit.
Hydraulic diagram
System version 1
19
Preparing for installation
5592 969 GB
Installation

APrimary side interface (see from
page 18)
BMin. 500 mm (for hydraulic
separation)
1Compact Energy Tower
5Overflow valve
6Diaphragm expansion vessel
heating circuit
7Temperature limiter underfloor
heating circuit (connection see
page 68)
8Plate-type heat exchanger
qP Underfloor heating circuit
qE DHW circulation pump
qR Natural cooling extension kit
qU KM BUS distributor
qI Vitotrol 200 remote control
qO Room temperature sensor
wP Extension kit for cooling circuit
with mixer
wQ Outside temperature sensor
wU DHW circulation extension
wI Heating circuit extension
wO Connection panel
eP Contact humidistat
eQ Circulation pump (secondary
cooling circuit pump)
eW Three-way diverter valve heating/
cooling
eE 2-way motorised ball valve
eR Frost stat
eT Circulation pump (primary cooling
circuit pump)
rQ Cooling circuit flow temperature
sensor
rW Cooling circuit mixer motor
Only in conjunction with
Vitocal 242:
wE Solar collector
wR Collector temperature sensor
wT Diaphragm expansion vessel,
solar circuit
wZ Solar circuit extension
System version 1 (cont.)
20
Preparing for installation
5592 969 GB